Information Guide for Tools and Fabrication Techniques

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Rebecca Morrison
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1 Information Guide for Tools and Fabrication Techniques Our Innovation. Your Imagination.

2 Table of Contents General Tooling Information Standard woodworking tools.. 4 Pocket screw.. 4 Heat guns and bending bars.. 4 Circular saw blades 4 Router bits....4 Up-cut and O-flute router bits..4-5 Profile bits CNC Information (General Guidelines) 5-6 Do not go past the shank Sloping lead-in...5 Best quality cuts....5 Speeds...5 Larger bits and profile bits Drilling Finishing Pass....6 Gluing King StarBoard ST...6 Recommendations.... 6

3 Mechanical Fasteners Bending King StarBoard ST Bending Bar Heat Gun Fabricating With Expansion and Contraction In Mind. 8 Temperature Changes Tips on do s and don ts... 8 Masking....8 Storage, Cleaning and General Care... 9 Storing Teak oil China markers and water-based markers Heat Pressure washing Nylon scrub pads Bleach Citrus cleaner, alcohol or mineral spirits Silicone spray.... 9

General Tooling Information Use standard woodworking tools to repair or fabricate components.

Plug cutters can also be used to plug holes in the material or cover counter sunk/counter bored screws.

all screws when working with King StarBoard ST* Pocket screw jigs are great for hiding screws. Heat guns can be used to bend King StarBoard ST around a radius.

4 General Tooling Information Use standard woodworking tools to repair or fabricate components. Hand routers, drills, circular saws, table saws, drill presses and orbital sanders all work well with King StarBoard ST. Plug cutters can also be used to plug holes in the material or cover counter sunk/counter bored screws. *Make sure to pilot hole and counterbore or countersink Make sure to pilot hole and counterbore or countersink all screws. all screws when working with King StarBoard ST* Pocket screw jigs are great for hiding screws. Heat guns can be used to bend King StarBoard ST around a radius. Heated bending bars also work well for making sharp corners. *See videos on for more details Circular saw blades. To create a crisp edge with a circular Pocket screw jigs are great for hiding screws. saw, use a good carbide blade with 60 teeth for a 10 blade and 40 teeth for a 7 1/2 blade. Router bits. Most router bit manufacturers classify King Starboard ST as a soft plastic. Router bits designed for soft plastics have a bit geometry that allows for a higher quality of cut, although standard woodworking bits will work fine. Carbide and high speed steel work well. 4 Up-cut, O-flute router bits are preferred for their superior chip removal. Down-cut and compression bits can re-weld Heat guns can be used to bend King StarBoard ST around a radius.

CNC Information (General Guidelines) Make sure your tool is chucked up in the tool holder as far as Use a good carbide blade with 60 teeth for a 10 blade and 40 teeth for a 7 1/2 blade.

This helps with chip removal and applies less stress to the spindle. Angled, sloping lead-ins can further reduce entry marks on the finished piece.

5 chips and cause cut quality issues if there is not sufficient room for chip removal. For profile bits, it is best to use bits with a rounded bottom. This helps reduce swirl marks. Chip relief is a major factor in the quality at the bottom of the cut. CNC Information (General Guidelines) Make sure your tool is chucked up in the tool holder as far as Use a good carbide blade with 60 teeth for a 10 blade and 40 teeth for a 7 1/2 blade. possible making sure not to go past the shank. It is always advised to do a sloping lead-in with a length relative to the depth of cut rather than a plunge. This helps with chip removal and applies less stress to the spindle. Angled, sloping lead-ins can further reduce entry marks on the finished piece. For the best quality cuts, do not cut deeper than the Up-cut, O-flute router bits are preferred for their superior chip removal. diameter of the bit in a single pass. This can be ignored if some quality can be sacrificed. For bits ¼ - ½ in diameter we use speeds of 18,000-22,000 RPMs and feed rates of inches per minute. Larger bits and profile bits may need to be ran at speeds as low as 8,000 RPMs and 100 inches per minute or slower. When drilling, we have found with our machine that pecking down with speeds of 4,000 RPMs, 75 inches per minute down feed and.125 per peck provides adequate For bits 1/4-1/2 in diameter, we use speeds of 18,000-22,000 RPMs and feed rates of inches per minute. 5

chip removal and minimizes chip windup on the bit. These speeds vary based on your machine, type of bit, amount of material being cut and the level of quality desired.

6 chip removal and minimizes chip windup on the bit. These speeds vary based on your machine, type of bit, amount of material being cut and the level of quality desired. If you feel that a finishing pass is necessary we recommend that you leave.015 of material on the initial pass. See CNC video at for further tips. Gluing King StarBoard ST Most woodworkers inherently use glue assemblies. glue adhesives Bonding with glue or adhesives is not a recommended method. Mechanical fasteners is the best technique for joining King Starboard ST. Mechanical fasteners and hardware should be stainless steel for all outdoor and indoor wet area applications to avoid rust and corrosion. Bending King StarBoard ST A bending bar can be used to produce a tight radius. First, cut a 90 groove at the desired bend location. The groove should be cut to a depth that leaves of material. The less material, the smaller the radius. The bending bar should be heated to F First, cut a 90 groove at the desired bend location. 6

Place the part on the bending bar and apply a weight of about 10-15 pounds per foot of part being bent evenly across the surface.

Look for a bead forming at the ends of the piece. Secure bending bar and remove piece from the bar. Residue left on the bar is common. A bending bar can be used to produce a tight radius.

7 Place the part on the bending bar and apply a weight of about pounds per foot of part being bent evenly across the surface. The weight can vary depending on the heat of the bar and is necessary to ensure that the part is in complete contact with the bending bar. Leave part on bar for 1-3 minutes. Look for a bead forming at the ends of the piece. Secure bending bar and remove piece from the bar. Residue left on the bar is common. A bending bar can be used to produce a tight radius. Clamp in place till cooled to ensure the bend holds. Slight over-bending may be necessary as the plastic tends to relax back to its initial position. A heat gun can be used to heat a part and bend it around a large radius. This takes some time and should not be rushed. Apply heat evenly to the part being bent. Do not get too close (stay 8-12 away from surface) or hover too long in one area. This may cause scorching and discolor or mar the surface. Continue this process until the piece can be bent to form the desired radius. Clamp in place till sufficiently cool. Over-bending may be necessary as the plastic tends to relax back to its initial Using a heat gun to bend around a large radius takes time and should not be rushed. position. 7

Fabricating with Expansion and Contraction in Mind King StarBoard ST expands and contracts at a rate of 1/32 per linear foot per 40 F temperature change.

8 Fabricating with Expansion and Contraction in Mind King StarBoard ST expands and contracts at a rate of 1/32 per linear foot per 40 F temperature change. DO pilot hole and counterbore or countersink all screws. If drastic temperature changes are possible, consider slotting the screw holes. DO NOT over-tighten screws. DO NOT install a product between two fixed objects, as this does not allow for expansion to occur and may result in a bowed piece (i.e. an outdoor cabinet tightly fitted between two walls or columns). Make sure to leave space. DO NOT butt parts together. A t-mold or similar cover can be used to cover the gap. See for more ideas on fabricating with expansion and contraction in mind. Masking King StarBoard ST is protected on one side with clear.002 (50 microns) thick masking. Testing has shown that leaving the masking on while machining, fabricating and routing helps ensure a pristine finish. The use of this product requires the knowledge of specific King StarBoard ST is protected on one side with clear masking. 8 fabrication and installation techniques.

Pen marks can usually be removed with household cleaners. Keep away from heat sources that exceed 180 F. Pressure washing and common detergents can be used to clean the surface.

9 Storage, Cleaning and General Care Store King StarBoard ST flat on a level surface. Do not stack more than two pallets high. Keep teak oil and other wood preservatives and stains away from King StarBoard ST components. They may permanently stain King StarBoard ST. Use china markers or water-based markers to draw patterns. Pen marks can usually be removed with household cleaners. Keep away from heat sources that exceed 180 F. Pressure washing and common detergents can be used to clean the surface. Nylon scrub pads and brushes should be used with care Nylon scrub pads and brushes should be used with care because excessive force can mar the finish. because excessive force can mar the finish. For resistant stains, apply bleach and allow it to soak in. Use citrus cleaner, alcohol or mineral spirits to remove grease or oil stains. Automotive silicone spray products or household furniture polish can help to hide scratches on the surface. To prevent slipping, do not use these products on walking surfaces. See for more information on Storage and cleaning. Use citrus cleaner, alcohol or mineral spirits to remove grease or oil stains. 9

10 Why King Plastic Corporation? Heritage King Plastic Corporation began as a small, family enterprise. Founded in 1968, King Plastic Corporation is a leading manufacturer of quality polymer sheets, slabs and massive shapes including several products pioneered by the company. Its polymers are sold worldwide through a network of top plastics distributors to customers who fabricate products for the Marine Industry (King StarBoard Brand), Signage, Food Service, Healthcare, Architectural, Industrial and other Markets. The company headquarters is a 150,000 square-foot manufacturing facility in North Port, Florida. The King family still maintains independent ownership and control. The same values that made the company so successful in the past still prevail today. Innovation King Plastic Corporation pioneered the first marine-grade polymer sheet, King StarBoard, which remains the dominant brand in the marine industry today. Since then, King has produced dozens of breakthrough products for a wide variety of industries, from food service to signage to giant slabs weighing more than 6,000 pounds. King continues to raise the bar with new products, new production techniques and new standards of excellence. Quality The King brand is synonymous with quality to those who know plastics. Our quality is achieved and maintained through rigorous development testing, premium materials, tight tolerances, proprietary processes (K-Stran ), thorough inspection, careful shipping, and training and hiring the best workforce in the industry. 10

11 Service King s commitment to quality doesn t end with products. The company s in-house sales team excels at product knowledge and developing long-term customer relationships. Its worldwide network of plastics distributors includes the best in the industry. Together, they make sure manufacturers and fabricators receive the right material, at the right price, right on time. Commodity Product Inventory While King Plastic Corporation s branded products enjoy a loyal following, the company also produces a wide variety of now-branded commodity products, King Performance Commodities. Thanks to expanded production and warehouse facilities, the company now has 200% more products in inventory ready for immediate shipping. Warranty King Plastic Corporation Limit of Warranty is money refunded or defective material replaced. All information and data provided at the time of writing is believed to be accurate and complete, but provided without any guarantee or responsibility of any kind, expressed or implied. It is recommended to pre-test all applications. The user must be aware that other safety measures may be required if not stated herein. 11

Our Innovation. Your Imagination. King Plastic Corporation has been developing and manufacturing quality polymer sheets, slabs and massive shapes for virtually any application since 1968.

12 Our Innovation. Your Imagination. King Plastic Corporation has been developing and manufacturing quality polymer sheets, slabs and massive shapes for virtually any application since Our comprehensive line of branded and commodity products is manufactured at our headquarters in North Port, Florida, and distributed worldwide. Our Innovation. Your Imagination N. Toledo Blade Blvd. North Port, FL USA P: F:

Polymer welding rods available

Fabrication and Finishing Use standard woodworking tools: table saws, table routers, drills, blades and bits. Carbide router bits with two to four flutes are recommended. Polymer welding rods available